Sumitomo Cyclo BBB4 User manual

Quick Start Guide
Manual 13.604.61.002 March 2016
Cyclo® BBB4
Bevel Buddybox®

Cyclo® BBB4 Quick Start Guide
Quick Start Guide
Cyclo® BBB4
Bevel Buddybox®
Table of Contents
Pages
Shaft and Bushing Installation 4
Taper-Grip Bushing 5
Keyed Hollow Bore 9
Shrink Disc 10
Torque Arm Mounting
Turnbuckle Type 12
Tie-Rod Type 15
T-Type 17
Flange Mount (Banjo) Type 19
Lubrication 22

Quick Start Guide Cyclo® BBB4 1
Safety Precautions
Review and adhere to the instructions in this manual to ensure:
• trouble-free Cyclo® BBB4 operation
• your rights to make a warranty claim.
Read this manual and all accompanying documents thoroughly before use. Understand the machine, information on
safety, and all precautions for correct operation. Sumitomo recommends that this manual is easily accessible for refer-
ence at the machine location.
• Only properly trained personnel should transport, install, align, wire, inspect, operate, and maintain
the unit.
• The user should install secondary safety devices for applications involving passenger transportation.
Failure to do so may result in personnel injury, death, and/or equipment damage.
• The user should install secondary safety devices for applications involving elevators. Failure to do so may
result in personnel injury, death, and/or equipment damage.
• Be sure to install and operate Cyclo® BBB4 speed reducers and gearmotors in compliance with
applicable local and national safety codes. Appropriate guards for rotating shafts are available from
factory.
CAUTION:
• Operate the unit only within its design and performance specifications; otherwise, injury or damage to the
system may occur.
• Keep hands and all foreign objects from the internal moving parts of the unit; otherwise, injury or damage
to the system may occur.
• Take damaged units off-line immediately and do not resume operation until properly repaired.
• Modifications or alterations of any kind to the unit will void the warranty and all subsequent claims.
• Do not remove the rating plate.
Inspection Upon Delivery
In order to avoid injury, ensure that the unit is in a stable position before unpacking.
• Verify that the unit received matches your order. Using the incorrect product may cause equipment
damage or personnel injury.
• Do not remove the nameplate from the unit.
Upon delivery, inspect the unit for damage that may have occurred during shipment. Notify the shipping company
immediately if you find any damage. Do not install or operate a damaged unit.
Upon receipt of the reducer/gearmotor, verify that:
• the model number on the unit nameplate matches the purchase order
• the unit was not damaged during shipping
• all bolts and nuts are fully tightened.
Please consult your Sumitomo agent, distributor, or sales office if you find any defects or if you have any questions.

2 Cyclo® BBB4 Quick Start Guide
Inspection of the Nameplate
When contacting Sumitomo’agent, distributor, or sales office about this product, please be prepared to provide the
following information from the reducer/ gearmotor nameplate:
• reducer or gearmotor model number (nomenclature)
• reduction ratio
• serial number
Nominal
Reduction
Ratio
Unit Model
Number
Unit Serial
Number
Non- Metallic Nameplate
Nominal
Reduction
Ratio
Unit Serial
Number
Unit Model
Number
Metal Nameplate
Inspection of Lubrication Method
• Oil lubricated units are shipped without oil, unless the customer specified otherwise when the unit was
ordered. Always fill the unit with the correct type and quantity of lubricant prior to operation.
• Certain models must be filled with lubricant in two separate locations, the bevel gear portion (output) and
the input portion.
Refer to the Lubrication section (page 21) in this manual for detailed lubrication information.
Installation
• Do not use the reducer/gearmotor for specifications other than those shown on the nameplate or in the
manufacturing specification documents. Personnel injury and/or equipment damage may occur.
• Do not place combustible material on or around the unit; fire may occur.
• Do not place any objects around the unit that will prohibit proper ventilation. Inadequate ventilation may
lead to high unit temperature and/or fire.
• Do not step on or hang from the unit. Excessive weight may cause component breakage leading to
personal injury and/or equipment damage.
• Do not touch the shaft, keyway, or motor fan with bare hands; injury may occur.
• For applications in which lubricant leaks could adversely affect operations (i.e., package handling, food
processing), place an oil pan below the unit to protect against contamination that may occur if oil seals
become damaged or worn.
• Do not remove the eye-bolt from the motor, should you need to remove the eye-bolt for any reason,
install a replacement bolt in the tapped hole to prevent water from entering the motor.

Quick Start Guide Cyclo® BBB4 3
Installation Location
Ambient Temperature Range: 14° - 104°F (-10° - 40°C)
Ambient Humidity: 85% or less
Altitude: 3,280 feet (1,000 m) or less
Atmosphere: The location should not contain corrosive gas, explosive gas, or
steam. The location should be free of dust and well ventilated.
Location: Indoor – free of dust and water
Consult Sumitomo when the unit will operate in conditions other than those specified above. Special unit
modifications may be required.
Units manufactured according to customer specified application requirements (i.e. outdoor modifications, high-
temperature modifications) are designed to operate within the specified environment.
Install the unit so inspection and/or maintenance procedures may be easily performed. Install all units that are not
shaft mounted on a sufficiently rigid base.
Operation After Storage
Before operating the unit after an extended storage period, ensure that non-metal parts, i.e., oil seals, o-rings, air
breather, have not deteriorated. Non-metal parts may deteriorate easily from exposure to ambient conditions (i.e.,
extreme temperatures, UV rays). Replace deteriorated parts with new before unit start-up.
After starting the unit, verify that there is no abnormal noise, vibration, and/or temperature rise. Immediately stop
the unit and call your local distributor, Original Equipment Manufacturer or Sumitomo directly if you observe any
abnormality.
Installation Angle
Mount the unit in the specified position for which it was ordered. Confirm the mounting position from the gearbox
nameplate.
Consult your local distributor, Original Equipment Manufacturer or Sumitomo directly if the mounting angle is to be
other than horizontal or vertical.
Severe Loading Conditions
For applications with severe vibration and/or frequent starts and stops, Sumitomo recommends the use of high-
strength mounting bolts of Grade 10.9 (or greater).

4 Cyclo® BBB4 Quick Start Guide
Taper-Grip® Installation onto
Driven Shaft
Prior to installation of the Cyclo® BBB4 onto the driven shaft,
ensure that the shaft length meets or exceeds the minimum shaft
engagement value “TT” detailed in Table 1.
Shaft Diameter
(in)
Tolerance
(in)
1-3/16 – 1-15/16 +0 / -0.0015
2 – 3-1/8 +0 / -0.0018
3-3/16 – 4-11/16 +0 / -0.0021
4-3/4 – 6-1/2 +0 / -0.0025
Cyclo® BBB4 Size TT (in) TT (mm)
4A 8.19 (208)
4B 9.53 (242)
4C 10.98 (279)
4D 12.83 (326)
4E 14.13 (359)
4F 16.22 (412)
Shaft Diameter
(mm)
Tolerance
(μm)
(30 - 50) (+0 / -39)
(50 - 80) (+0 / -46)
(80 - 120) (+0 / -54)
(120 - 180) (+0 / -63)
Table 1. Driven Shaft Tolerance and Minimum Shaft
Engagement (TT)
TT
Taper-Grip® Bushing
Socket Head Cap Screws
Thrust Collar
Installation onto the Driven Machine
• Before coupling the reducer/gearmotor to the machine,
verify the appropriate/desired rotation of the machine.
Differences in the rotational direction may cause
personnel injury and/or equipment damage.
• Before operating the unit, ensure that all safety guards
around the rotating components are in-place and secure.
Failure to do so may result in personal injury.
Do not operate shaft mounted units until the torque arm has been attached to the unit and fixed to a
rigid structure. The Torque Arm prevents counter-rotation during unit operation. Refer to Torque Arm
Installation section of this manual (page12).
CAUTION: The Cyclo® BBB4 must be externally supported prior to insertion of driven shaft into bushing.
External support MUST be maintained until unit is secured and mounting bolts have been tightened to the
appropriate torque.
External
Support

Quick Start Guide Cyclo® BBB4 5
1
Remove bushing cover if unit was supplied with one.
2
Loosen socket head cap screws.
3
Remove (unscrew) Taper-Grip® bushing from the unit.
4
Clean all grease, oil and/or anti-seize grease from the driven shaft.
Failure to do so could result in damage to shaft.
Slide Taper-Grip® bushing onto driven shaft.
Clean Driven
Shaft

6 Cyclo® BBB4 Quick Start Guide
5
Inspect and test Taper-Grip® bushing on shaft.
• Check shaft for burrs, corrosion, or warpage. Repair or
replace shaft as necessary.
• Slide bushing back and forth along shaft, checking for
surface irregularities and fit.
• Verify bushing is sized correctly for the shaft diameter.
6
Remove Taper-Grip® bushing from driven shaft.
7
Apply a thin layer of anti-seize grease to the male threads of the
Taper-Grip® bushing only.
Ensure that the anti-seize grease does not enter the Taper-
Grip® bushing bore.
Do not apply anti-seize grease to the female threads in the
hub.
Apply thin layer of
anti-seize grease to male
threads of bushing only.
Do not apply anti-seize grease
to the female threads in the
hub.

Quick Start Guide Cyclo® BBB4 7
8
Screw Taper-Grip® bushing into Cyclo® BBB4 leaving approximately
1 mm gap between the bushing flange and thrust collar.
Do not apply grease, oil, or anti-seize grease to the
driven shaft or the bushing bore before placing the unit
onto driven shaft. Use of these friction-minimizing products
will adversely affect the ability of the unit to transmit
torque.
CAUTION: The Cyclo® BBB4 must be externally supported
prior to insertion of driven shaft into bushing. External
support MUST be maintained until all bushing socket
head cap screws have been tightened to the appropriate
operational torque.
9
Mount or slide the Cyclo® BBB4 onto the driven shaft
Do not rock or pry the unit.
10
Screw Bolts into Taper-Grip® bushing.
• Lightly oil threads of each bolt before inserting.
• Finger tighten each bolt to secure in place.
• Be sure to maintain the 1 mm (approximate) gap
between the thrust collar and the bushing flange.
Feeler Gauge
Bushing
Flange
Thrust Collar

8 Cyclo® BBB4 Quick Start Guide
11
Tighten bushing bolts to the correct torque value.
• Following a star pattern, use a torque wrench to
gradually tighten each socket head cap screw in 20%
increments.
• Refer to Table 2, Taper-Grip® Bushing Bolt Tightening
Torques, for the correct operational screw torques.
12
In order to prevent corrosion, apply grease to the exposed portion of the
driven shaft.
• After installing and tightening the bushing bolts with
a torque wrench, apply grease or an anti-corrosion
product to the exposed portion of the shaft.
13
After the reducer has been running for 20 to 30 hours, re-torque the
screws to the values in Table 2. Screw torques should be subsequently
checked at normal service intervals (i.e. every 6 months).
14
For units that include a bushing safety cover, reinstall the guard over
the Taper-Grip® bushing.
Do not operate unit until the torque arm has been attached
to the unit and fixed to a rigid structure. The torque arm
prevents counter-rotation during unit operation. Refer
to torque arm Installation section in this manual for
instructions.
12
3
4
5
6
Table 2. Taper-Grip® Bushing Bolt Tightening Torques
Cyclo® BBB4
Size Screw Qty x Size
Screw Torque
ft-lb (Nm)
4A 6 x M12 56 (75)
4B 6 x M12 104 (140)
4C 6 x M16 185 (250)
4D 6 x M16 223 (300)
4E 8 x M16 223 (300)
4F 10 x M16 223 (300)
Apply grease to
exposed portion
of driven shaft

Quick Start Guide Cyclo® BBB4 9
Keyed Hollow Bore Installation onto
Driven Shaft
1
Apply molybdenum disulfide grease or similar anti-seize compound,
to the driven shaft surface and inside the reducer keyed hollow bore.
2
Align the driven shaft with the reducer/gearmotor bore and carefully
slide unit onto the driven shaft.
If the fit is tight, strike on the keyed hollow bore with a soft
mallet to assist in the assembly.
If using a soft mallet during installation, strike only against
the unit’s steel keyed hollow bore. Do not strike the reducer
housing or oil seal, damage to the bearings, the housing,
and/or the seals may occur.
Note: If the fit is tight, you may use a jig such as the one shown here
to ease assembly. Sumitomo does not supply a mounting jig. This
information is provided for reference only.
Grease
Size a b c d e
CC (ISO/JIS) A2 Bearing Nut Threaded Rod
4A 3 25 51104 M16 M16 x 250
4B 65 25 51105 M20 M20 x 300
4C 75 25 51105 M20 M20 x 300
4D 85 35 51107 M24 M24 x 400
4E 100 35 51107 M24 M24 x 400
4F 120 46 51109 M30 M30 x 450
Table 3. Jig Dimensions
Spacer b
Retaining Ring a
Ball
Bearing
c
Threaded Rod e Nut d
A2
Unit: mm

10 Cyclo® BBB4 Quick Start Guide
3
Once driven shaft has been completely inserted into the unit’s keyed
hollow bore, secure the shaft in place using a keeper plate as shown
in this example, or some other means of securing the unit to the
driven shaft.
Do not operate unit until the torque arm has been
attached. Refer to the Torque Arm Installation (page12)
section in this manual for instructions.
Shrink Disc Type Hollow Bore Installation
onto Shaft
Before placing unit onto driven shaft, do not apply grease,
oil, or anti-seize grease to the entire driven shaft or to the
bore of the shrink disc. Use of these friction-minimizing
products will adversely affect the ability of the unit to
transmit torque.
Never tighten locking screws before shaft installation. Inner ring may
become permanently contracted even at low tightening torques.
1
Clean and degrease contact surfaces; reducer shaft and bore, and the
machine driven shaft.
Apply Molykote 321 or an equivalent dry film lubricant to the driven
shaft projection opposite from the shrink disc.
Do Not apply any friction minimizing compound to the
driven shaft at or near the shrink disc.
2
Align the driven shaft with the bore of reducer/gearmotor bore and
carefully slide unit onto the driven shaft.
If the fit is tight, strike on the reducer hollow bore with a mallet to assist in
the assembly.
If using a mallet during installation, strike only against the
unit’s steel hollow bore. Do not strike the reducer housing
or oil seal, damage to the bearings, the housing, and/or the
seals may occur.
Note: If the fit is tight, use a jig such as the one shown in Table 3 to
ease assembly. Sumitomo does not supply a mounting jig. This
information is provided for reference only.
Degrease
these areas
Apply Molykote 321
to this shaft area only

Quick Start Guide Cyclo® BBB4 11
3
Set the (untightened) shrink disc on the reducer shaft.
4
Tighten bolts to the correct torque value.
• For 3-piece design shrink disc, make sure that both plates
are parallel when tightening bolts.
• After confirming that the shrink disc is set correctly,
tighten the bolts uniformly, in a clockwise pattern while
keeping both plates parallel (not diagonally or ‘star’
pattern).
• It is recommended to tighten respective bolts by 30
degrees each time – until the specified torque is reached.
5
For units with a safety cover, reinstall the guard over the shrink disc.
Do not operate unit until the torque arm has been
attached. Refer to the Torque Arm Installation section in
this manual for instructions.
Size Model (Typical) Bolt Bolt Torque
ft-lb (Nm)
4A TAS-3071-55 x 68 10 x M6x25 ISO/JIS grade 10.9 9(12)
4B TAS-3071-65 x 80 7 x M8x30 ISO/JIS grade 12.9 26 (34)
4C TAS-3071-75 x 100 12 x M8x35 ISO/JIS grade 12.9 26 (34)
4D TAS-3071-85 x 110 9 x M10x40 ISO/JIS grade 12.9 51 (68)
4E TAS-3071-100 x 140 10 x M12x45 ISO/JIS grade 12.9 87 (118)
4F TAS-3071-120 x 165 8 x M16x55 ISO/JIS grade 12.9 214 (290)
Table 4. Shrink Disc Size and Tightening Toque

12 Cyclo® BBB4 Quick Start Guide
Turnbuckle Torque Arm Installation
Procedure
1
Attach the torque arm threaded extension rod to the bevel housing,
at the housing corner eyelet, using the appropriate nut, bolt and
lockwasher.
Insert the bolt through the brackets, torque arm sleeve (if supplied)
and reducer housing eyelet.
Place the lockwasher on the bolt and secure with nut.
Item Description Item Description
1 Hex Nut 7 Lock Washer
2Lock Washer 8 Fulcrum Mounting Bracket
3Threaded Extension Rod 9 Hex Bolt
4 Turnbuckle 10 Locking Nut (if supplied)
5 Threaded Arm 11 Locking Nut (if supplied)
6 Hex Nut 12 Hex Bolt
BBB4 Size Bolt Size[1] Torque
ft-lb (Nm)
4A M16 x 75 152 - 167 (206 – 227)
4B M20 x 100 290 – 319 (392 – 431)
4C M24 x 105 507 - 558 (686 – 755)
4D M24 x 125 507 - 558 (686 – 755)
4E M24 x 125 507 - 558 (686 – 755)
4F Consult Factory
Note: [1] Bolt ISO/JIS Class 8.8
1
3
4
2
5
67
8
9
1011
12
Table 6. Bolt Tightening Torque
Table 5. Turnbuckle Type Torque Arm Parts
Insert Bolt
Tighten Nut
Figure 1. Turnbuckle Type Torque Arm

Quick Start Guide Cyclo® BBB4 13
2
Install the turnbuckle onto the threaded extension rod (gearbox side)
and then threaded arm (foundation side) to the turnbuckle
If the assembly was supplied with hex nuts to secure the turnbuckle,
install the nuts loosely, ensuring the left hand nut is used on the
threaded arm, prior to installing the turnbuckle and threaded arm.
3
Position the torque arm so
it will be in tension during
unit operation and mount
the fulcrum mounting
bracket to suitable
structure or foundation.
Mounting hardware for
fulcrum mounting bracket
are NOT supplied by
Sumitomo.
4
Position the torque arm as close as possible to 90° relative to the unit
output bore / driven equipment shaft.
Sumitomo does not recommend the use of multiple torque arm
assemblies to achieve a greater overall length.

14 Cyclo® BBB4 Quick Start Guide
5
Assemble the threaded arm to the fulcrum mounting bracket,
as shown. Some adjustment of the turnbuckle may be required
to lengthen or shorten the overall length. Secure it with the
appropriate nut, bolt and lockwasher.
• Insert the bolt through the brackets and threaded arm
eyelet.
• Place the lockwasher on the bolt and secure with nut.
6
If turnbuckle hex nuts were supplied, secure the turnbuckle position
by adjusting the previously installed turnbuckle nuts.
BBB4 Size Bracket
Bolt Size[1]
Torque
ft-lb (Nm)
4A M16 x 65 152 - 167 (206 – 227)
4B M16 x 80 152 - 167 (206 – 227)
4C M16 x 80 152 - 167 (206 – 227)
4D M16 x 80 152 - 167 (206 – 227)
4E M16 x 80 152 - 167 (206 – 227)
4F Consult Factory
Table 7. Bolt Tightening Torque
BBB4 Size Nut Size[1] Torque
ft-lb (Nm)
4A M20 290 – 319 (392 – 431)
4B M24 507 - 558 (686 – 755)
4C M24 507 - 558 (686 – 755)
4D M24 507 - 558 (686 – 755)
4E M24 507 - 558 (686 – 755)
4F Consult Factory
Table 8. Nut Tightening Torque
Note: [1] Bolt ISO/JIS Class 8.8
Note: [1] Bolt ISO/JIS Class 8.8
Mounting
Bracket
Bolt
Threaded Arm
Lock Washer
Nut

Quick Start Guide Cyclo® BBB4 15
Tie Rod Torque Arm Installation
Procedure
1
Assemble the torque arm mounting brackets or wishbone clevis to
the threaded arm, and attach the torque arm assembly to the bevel
housing, at the housing corner eyelet, using the pin and cotter pin.
Tighten mounting bolts according to the values listed in Table10.
• Insert the clevis pin through the brackets and housing
eyelet.
• Insert the cotter pin into clevis pin and secure assembly.
Item Description Item Description
1Flat Washer 7 Rubber Bushing
2 (2) Mounting Brackets or (1) Clevis 8 Washers
3 Hex Bolt 9 Lock Washer
4 Spacer 10 Clevis Pin
5 Threaded Arm 11 Cotter Pin
6 Hex Hut
BBB4 Size Bracket
Bolt Size[1]
Torque
ft-lb (Nm)
4A 2 x M16 152 – 167 (206 – 227)
4B 2 x M20 290 – 319 (392 – 431)
4C 2 x M24 507 – 558 (686 – 755)
4D 2 x M24 507 – 558 (686 – 755)
4E 2 x M24 507 – 558 (686 – 755)
4F Consult Factory
Table 10. Bracket Bolt Tightening Torque
Note: [1] Bolt ISO/JIS Class 8.8
123
56 6
7
8
4
2
4
9
10
11
Table 9. Tie Rod Type Torque Arm Parts
Figure 2. Tie Rod Type Torque Arm

16 Cyclo® BBB4 Quick Start Guide
2
Position the torque arm so it will be in tension during unit operation.
3
Position the torque arm as close as possible to 90° relative to the unit
output bore / driven equipment shaft.
Sumitomo does not recommend the use of multiple torque
arm assemblies to achieve a greater overall length.
4
After inserting the torque rod into the mounting surface, carefully
tighten nuts on either side of torque rod.
Do not over tighten nuts. Tighten to point where rubber
bushings can still be hand rotated when the unit is turned
off.
Before starting unit, verify the following:
• The torque arm will be in tension when the unit is in
operation.
• The torque arm is aligned with the reducer housing.
• The torque arm is perpendicular to the axis of the
output / driven shaft.
• The threaded arm is not touching the reducer housing.
Customer
Mounting
Surface
Bushing are free to
rotate by hand
CW LSS
Unit Rotation

Quick Start Guide Cyclo® BBB4 17
T-Type Torque Arm Installation
Procedure
1
Attach the T-Type Torque Arm Bracket to the Cyclo® BBB4 using the supplied
mounting hardware.
Tighten mounting bolts according to the values listed in Table 7
2
Place washer and rubber bushing on bolt.
Insert torque arm bolt (supplied by customer) through mounting tab
on Banjo torque arm.
Make sure bolt is parallel to T-Type Torque Arm side
when fully installed.
3
Follow these steps to attach the mounting angle bracket:
• Place rubber bushing and mounting angle bracket on
the bolt.
• Verify that the mounting angle bracket hole is the correct
diameter for customer supplied bolt.
• Place remaining bushing, washer and two nuts on
the bolt.
Do not over-tighten nuts. Tighten to point where rubber
bushings can still be hand rotated.
Torque Arm
Bracket
Mounting Bolts
BBB4 Size Bracket
Bolt Size[1]
Torque
ft-lb (Nm)
4A 2 x M16 152 – 167 (206 – 227)
4B 2 x M20 290 – 319 (392 – 431)
4C 2 x M24 507 – 558 (686 – 755)
4D 2 x M30 1014 – 1115 (1373 – 1510)
4E 2 x M30 1014 – 1115 (1373 – 1510)
4F T-Type Not Available
Note: [1] Bolt ISO/JIS Class 8.8
Table 11. T-Bracket Bolt Torques
Washer
Rubber Bushing
When installed,
bolt must be
parallel to this
surface
Washer
Rubber Bushings
Mounting Angle
Bracket
(Customer
Supplied)
Nuts
(Customer Supplied)
Unit Size Bracket Tab Bore Typical Bolt Size [1]
4A Ø18mm M16
4B Ø18mm M16
4C Ø22mm M20
4D Ø26mm M24
4E Ø33mm M30
Note [1] Bolt class should be greater or equal to ISO/JIS Class 8.8. Application with
multiple start/stops and/or shock loading should use ISO/JIS 10.9 at a minimum.
Table 12. T-Bracket Mount Dimensions

18 Cyclo® BBB4 Quick Start Guide
Top View
4
Confirm that the rubber bushings can still be rotated by hand. This
indicates the bushing has not been over-tightened.
Compressed bushings will not allow the bushings to properly absorb
the loads of the shaft mounted gearbox. This can lead to premature
failure.
Mounting angle bracket must be secured to the machine
structure.
5
Confirm the mounting angle bracket does not interfere with the
torque arm. There should be no metal-to-metal contact between
the two during a complete revolution of the driven equipment.
Metal-to-Metal contact between these two components
may lead to catastrophic failure of the reducer/ gearmotor.
Bushing are
free to rotate by
hand